Method for manufacturing a midplane

ABSTRACT

A method for manufacturing a mid-plane. a multi-layer board having a connection assembly is provided and a layer with a channel formed therein to define a perimeter of a connector area is provided. The layer is bonded to the multi-layer board such that the connector area overlaps the part of the connection assembly of the multi-layer board. At least a portion of the connector area in the layer is removed to expose the connection assembly of the multi-layer board. A rigid multilayer is also disclosed. The rigid multilayer includes a multi-layer board and a layer. The multi-layer board has a connection assembly. The layer has a channel formed therein to define a perimeter of a connector area. The layer is bonded to the multi-layer board such that the connector area overlaps the connection assembly of the multi-layer board. The connector area can then be removed such as by depth controlled routing. As will be understood by one skilled in the art, the depth tolerance is not critical because the layer is pre-formed with the channel prior to formation of the rigid multi-layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent application claims priority to the provisional patent application filed on Jul. 8, 2003 and identified by U.S. Ser. No. 60/485,765, the entire content of which is hereby incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

SUMMARY OF THE INVENTION

In general, the present invention relates to method for manufacturing a mid-plane. In the method, a multi-layer board and a layer are provided. The layer is preferably a dielectric layer. The multi-layer board has a connection assembly. The layer has a channel formed therein to define a perimeter of a connector area. The layer is bonded to the multi-layer board such that the connector area overlaps the connection assembly of the multi-layer board. Then, at least a portion of the connector area in the layer is removed to expose the connection assembly of the multi-layer board.

The present invention also relates to a rigid multilayer. The rigid multilayer includes a multi-layer board and a layer. The layer is preferably a dielectric layer. The multi-layer board has a connection assembly. The layer has a channel formed therein to define a perimeter of a connector area. The layer is bonded to the multi-layer board such that the connector area overlaps the connection assembly of the multi-layer board. The connector area can then be removed such as by depth controlled routing to expose the connection assembly of the multi-layer board. As will be understood by one skilled in the art, the depth tolerance is not critical because the layer is pre-formed with the channel prior to formation of the rigid multi-layer.

The layer is preferably bonded to the multi-layer board with a non-flowable adhesive or a low flowable adhesive. The non-flowable adhesive or low flowable adhesive can be certain types of pre-preg known in the art. The channel pre-formed in the layer prevents any flow of the adhesive from entering the connector area. Thus, the adhesive does not interfere with or otherwise damage the connection assembly formed in the multi-layer board.

Other advantages and features of the present invention will become apparent to one skilled in the art when the following detailed description is read in conjunction with the attached drawings and the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a mid-plane constructed in accordance with the present invention.

FIG. 2 is a cross-sectional view of two multi-layer circuit boards constructed in accordance with the present invention.

FIG. 3 is a cross-sectional view of a first and second metallic foils and bonding materials utilized in the construction of the mid-plane depicted in FIG. 1.

FIG. 4 is a cross-sectional view of a laminate stack formed of the multi-layer boards depicted in FIG. 2, combined with the metallic foils and bonding materials depicted in FIG. 3.

FIG. 5 is a cross-sectional view of the laminate stack depicted in FIG. 4, laminated together to form a rigid multi-layer product ready for finishing.

FIG. 6 is a cross-sectional view of another embodiment of a laminate stack, which is similar to FIG. 5 with the exception that the conductive layer has been removed and an electrical connector has been added.

FIG. 7 is a cross-sectional view of the finished mid-plane.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, and in particular to FIG. 1, shown therein and designated by a reference numeral 10 is a mid-plane constructed in accordance with the present invention. The mid-plane 10 is provided with a first side 12 and a second side 14. The mid-plane 10 is also provided with at least two multi-layer boards 16, which are designated by the reference numeral 16 a and 16 b for purposes of clarity. Each of the multi-layer boards 16 defines at least one and preferably more than one connector area 20. The connector areas 20 are designated for purposes of clarity by the referenced numerals 20 a, 20 b, 20 c and 20 d. The connector areas 20 a and 20 b are positioned adjacent to the first side 12. The connector areas 20 c and 20 d are positioned adjacent to the second side 14. As will be discussed in more detail below, the connector areas 20 are designed to permit interconnection with connectors 22 such that the connectors 22 can be mounted on both sides, i.e., the first side 12 and the second side 14, of the mid-plane 10. The connectors 22 are designated for purposes of clarity with the reference numerals 22 a, 22 b, 22 c, and 22 d. The connectors 22 are connected to the multi-layer boards 16 by any suitable connection assembly 24, which is illustrated in FIG. 1 by way of press fit connectors 26 by way of example. Only three of the press fit connectors 26 are labeled In FIG. 1 for purposes of clarity.

The mid-plane 10 is also provided with first and second metallic foils 30 and 32. The first metallic foil 30 is connected to the multi-layer board 16 a via a bonding material 34. The second metallic foil 32 is connected to the multi-layer board 16 b via a bonding material 36. The multi-layer board 16 a is connected to the multi-layer board 16 b by way of a bonding material 38. The bonding materials 34, 36 and 38 can be any suitable material capable of rigidly affixing the metallic foils 30 and 32, and the multi-layer boards 16 a and 16 b together to form the mid-plane 10 as a rigid structure. For example, the bonding materials 34, 36 and 38 can be an uncured pre-preg material. The bonding materials 34 and 36 are preferably low flowable adhesives or non-flowable adhesives, such as certain types of pre-preg known in the art.

It should be noted that the first and second metallic foils 30 and 32 can be provided with predetermined conductive patterns thereon including vias or other types of electrical interconnections for connecting the first and second metallic foils 30 and 32 to the respective multi-layer boards 16 a and 16 b so that at least two independent circuits are formed on either side of the mid-plane 10. In other words, the first metallic foil 30 is electrically interconnected with the multi-layer board 16 a to form at least one independent circuit. Likewise, the second metallic foil 32 is interconnected with the multi-layer board 16 b to form at least one independent circuit. It should be noted that the circuits on the multi-layer boards 16 a and 16 b can be interconnected, if desired, by vias or other suitable conductive paths formed in the mid-plane 10.

FIGS. 2-5 illustrate one method for forming the mid-plane 10. FIGS. 2-5 will now be described in more detail. However, it should be understood that other manners in constructing the mid-plane 10 can be used.

Shown in FIG. 2 are the multi-layer boards 16 a and 16 b. The connection assembly 24 of the multi-layer board 16 a includes a plurality of electrical connectors 40 defining a plurality of holes 42. Likewise, the connection assembly 24 of the multi-layer board 16 b is provided with a plurality of electrical connectors 46 defining a plurality of holes 48. The electrical connectors 40 and 46 are sized so that the holes 42 and 48 will matingly receive the press fit connectors 26. The electrical connectors 40 and 46 form a part of the connection assembly 24 referred to above in the preferred embodiment shown herein. The sizes of the holes 42 and 48 are preferably equal to the pressfit sizes.

The multi-layer boards 16 a and 16 b can be characterized as buried via products complete with a surface finish (not shown) such as an ENIG finish.

Shown in FIG. 3 is the first and second metallic foils 30 and 32, as well as the bonding materials 34 and 36. The first and second metallic foils 30 and 32 are substantially identical in construction and function. For purposes of brevity, only the first metallic foil 30 will be described in detail hereinafter. The first metallic foil 30 is provided with a conductive layer 50, and a dielectric layer 52. The conductive layer 50 is constructed of any type of suitable conductive material, such as aluminum, copper or the like. Typically, the conductive layer 50 will be constructed of copper. The conductive layer 50 is etched or otherwise formed into the shape of a predetermined pattern for electrically connecting a variety of components and/or circuits provided in the multi-layer board 16 a. The dielectric layer 52 can be constructed of any suitable type of dielectric material, such as FR4. The connector areas 20 are defined in the dielectric layer 52 by creating a channel 54 about a perimeter of a connector area 20. The channel 54 is designated in FIG. 3 by the reference numerals 54 a, 54 b, 54 c and 54 d for purposes of clarity. The channels 54 a, 54 b, 54 c and 54 d serve at least two purposes. The first purpose is to prevent the bonding materials 34 and 36 from bleeding or flowing into the connector areas 20 a, 20 b, 20 c and 20 d. The other purpose is to permit removal of the first and second metallic foils 30 and 32 in the connector areas 20 a, 20 b, 20 c and 20 d in a subsequent manufacturing step, which will be discussed in more detail in FIG. 7. The channels 54 a, 54 b, 54 c, and 54 d can be formed in any suitable manner, such as with a router or a laser. The bonding materials 34 and 36 are preferably pre-formed with cutouts so that the bonding materials 34 and 36 surround the channels 54 a, 54 b, 54 c and 54 d. In one embodiment (not shown) the channels 54 a, 54 b, 54 c and 54 d may be formed in a conductive layer, rather than the dielectric layer 52.

The bonding materials 34 and 36 are provided adjacent to the dielectric layer 52 and extend generally about the dielectric layer 52, with the exception of the portions of the dielectric layer 52 provided in the connector areas 20 a, 20 b, 20 c and 20 d.

Shown in FIG. 4 is a laminate stack 60 formed of the multi-layer boards 16 a and 16 b, first and second metallic foils 30 and 32, and bonding materials 34, 36 and 38. The laminate stack 60 is then subjected to conditions which causes the bonding materials 34, 36 and 38 to bond the first and second metallic foils 30 and 32, and the multi-layer boards 16 a and 16 b together, substantially as shown in FIG. 5. For example, when the bonding materials 34, 36 and 38 are constructed of pre-preg, the laminate stack 60 is subjected to heat and pressure to form a rigid multi-layer 62 suitable for finishing.

In another embodiment a rigid multi-layer 62 a can be produced, as shown in FIG. 6. The rigid multi-layer 62 a is similar to the rigid multi-layer 62 except the conductive layer 50 has been removed and an electrical connector 40 a has been added. The rigid multi-layer 62 a is ready to be finished as standard. For example, drilling, plating, pattern outerlayers and surface finish may be utilized to finish the rigid multi-layer 62 a.

As shown in FIG. 7, the rigid multi-layer 62 can be profiled in a well known manner, but first, the connector areas 22 a, 22 b, 22 c are opened to permit insertion of the connectors 22 a-b by cutting or removing materials adjacent to the channels 54 a-d. As will be understood by one skilled in the art, the depth tolerance is not critical because the first and second metallic foils 30 and 32 are pre-formed with the channels 54 a-d prior to formation of the rigid multi-layer 62. In one embodiment, the connector areas 22 a-d are opened by using depth control routing of the cambers.

The mid plane 10 can then be used in a well known manner. That is, the connectors 22 with the press fit connectors 26 are connected through the rigid multi-layer by inserting the press fit connectors 26 in through the holes 42 and 48 in the rigid multi-layer 62. The use of mid planes is known in the art, and no more comments are believed necessary to teach one skilled in the art how to use the mid plane 10 in view of the other detailed description contained herein.

It should be understood that the foregoing sets forth examples of the present invetion. Thus, changes may be made in the construction and operation of the various components, elements and assemblies described herein and changes may be made in the steps or the sequence of steps of the methods described hereinwithout departing from the spirit and the scope of the invention as defined in the following claims. 

1. A method for manufacturing a mid-plane, comprising the steps of: providing a multi-layer board having a connection assembly; providing a layer with a channel formed therein to define a perimeter of a connector area; bonding the layer to the multi-layer board such that the connector area overlaps the part of the connection assembly of the multi-layer board; and removing at least a portion of the connector area in the layer to expose the connection assembly of the multi-layer board.
 2. The method of claim 1, wherein the layer is bonded to the multi-layer board so as to form a space between the layer and the connection assembly of the multi-layer board.
 3. The method of claim 1, wherein the layer is bonded to a conductive layer to form a metallic foil.
 4. The method of claim 3, wherein the metallic foil is a single sided copper clad laminate whereby the conductive layer is formed of copper and the layer is applied to only one side of the conductive layer of copper.
 5. The method of claim 1, wherein the step of removing at least a portion of the connector area is defined further as removing the connector area by depth controlled routing along the channel.
 6. The method of claim 1, wherein the multi-layer board is coated with a surface finish prior to the step of bonding the layer to the multi-layer board.
 7. A method for manufacturing a mid-plane, comprising the steps of: providing two multi-layer boards with each having a connection assembly; providing first and second layers with each having a channel formed therein to define a perimeter of a connector area; bonding the first layer to one of the multi-layer boards and the second layer to the other one of the multi-layer boards such that the connector areas overlap the respective connection assemblys of the multi-layer boards; bonding the multi-layer boards together to form a rigid multilayer wherein the first layer is positioned on one side of the rigid multilayer and the second layer is positioned on an opposite side of the rigid multilayer; and removing at least a portion of the connector areas in the first and second layers to expose the respective connection assemblys.
 8. The method of claim 7, wherein each of the layers are bonded to the multi-layer boards so as to form a space between the layer and the connection assembly of the multi-layer board.
 9. The method of claim 7, wherein the layer is bonded to a conductive layer to form a metallic foil.
 10. The method of claim 9, wherein the metallic foil is a single sided copper clad laminate whereby the conductive layer is formed of copper and the layer is applied to only one side of the layer of copper.
 11. The method of claim 7, wherein the step of removing at least a portion of the connector areas is defined further as removing the connector areas by depth controlled routing along the channels.
 12. The method of claim 7, wherein the multi-layer boards are coated with a surface finish prior to the step of bonding the layer to the multi-layer board.
 13. A rigid multilayer, comprising: a multi-layer board having a connection assembly; a layer having a channel formed therein to define a perimeter of a connector area, the layer bonded to the multi-layer board such that the connector area overlaps the connection assembly of the multi-layer board.
 14. The rigid multilayer of claim 13, wherein the layer has a first side in which the channel is formed and wherein the first side of the layer faces the multi-layer board.
 15. The rigid multilayer of claim 13, wherein the connector area of the layer is spaced a distance from the multi-layer board.
 16. The rigid multilayer of claim 13, further comprising a conductive layer extending over the layer such that the layer is positioned between the conductive layer and the multi-layer board. 